A rapid two-step process to prepare a high-throughput, efficient, reusable superhydrophobic–superoleophilic stainless steel mesh for oil/water separation

Currently, due to the industrial development, the direct discharge of large amounts of oil-containing wastewater has led to serious water pollution. It is necessary to develop an efficient, durable, and high-throughput material for oil–water separation. To achieve this, we prepared a nickel (Ni) coating with a loose leaf-like micro/nanostructure on the surface of stainless steel mesh (SSM), imparting it with superhydrophobic and superoleophilic properties. The deposition of ions onto the substrate was carefully controlled by adjusting the deposition parameters. Subsequently, the as-prepared Ni coating was further modified using a solution of perfluorooctyltriethoxysilane (PFOTS) in ethanol to obtain a PFOTS/Ni mesh (PNM) with excellent superhydrophobic–superoleophilic properties. Wettability tests revealed that the water contact angle (WCA) and oil contact angle (OCA) of the PNM, prepared under the optimized deposition conditions, were 161 ± 1° and 0°, respectively, with a water sliding angle (WSA) of less than 10°. Importantly, the PNM demonstrated remarkable mechanical stability in blade scratch and tape peel tests, as well as excellent chemical stability in acid-alkali resistance and electrochemical corrosion tests. And, the PNM exhibited remarkable self-cleaning capability. Additionally, PNMit filters displayed outstanding efficiency in separating oil and water (reaching 91.5%) and remarkable durability. The results indicate that the well-designed superhydrophobic–superoleophilic SSM exhibits advantages such as simple fabrication, low cost, high reusability, and strong robustness. It holds great potential for practical applications in the treatment of oily wastewater and oil spill remediation.